System and method for textile positioning

ABSTRACT

A circular needle loom comprises a stationary bed plate for receiving a spiral textile. Engagement members may be disposed next to the stationary bed plate, such that the engagement members interface with a positional structure of the spiral textile that is used to position and rotate the spiral textile around the stationary bed plate. A conical roller deploys the spiral textile on the stationary bed plate. The engagement members rotate the spiral textile around the stationary bed plate until a predetermined number of layers are deposited on the stationary bed plate. 
     A spiral textile comprises a weft tow that extends from an inside diameter to an outside diameter, and a positional structure, such as a sacrificial edge and/or loop, is located next to and/or is attached to the weft tow. The positional structure facilitates positioning the spiral textile in a desired manner with respect to the circular needle loom in order to create a needled preform.

FIELD OF INVENTION

This invention generally relates to positioning and securing a textile,and more particularly, to systems and methods for positioning andsecuring a spiral textile on a rotational bed plate or entraining atextile on a stationary bed plate to needle the spiral textile into acircular preform.

BACKGROUND OF THE INVENTION

Carbon/carbon (“C/C”) parts are employed in various industries. Anexemplary use for C/C parts includes using them as friction disks suchas aircraft brake disks, race car brake disks, clutch disks, and thelike. C/C brake disks are especially useful in such applications becauseof the superior high temperature characteristics of C/C material. Inparticular, the C/C material used in C/C parts is a good conductor ofheat and thus is able to dissipate heat away from the braking surfacesthat is generated in response to braking. C/C material is also highlyresistant to heat damage, and is thus capable of sustaining frictionbetween brake surfaces during severe braking, without a significantreduction in the friction coefficient or mechanical failure.

C/C material is generally formed by utilizing continuous oxidizedpolyacrylonitrile (PAN) fibers, referred to as “OPF” fibers. Such OPFfibers are the precursors of carbonized PAN fibers and are used tofabricate a preformed shape using a needle punching process. OPF fibersare layered in a selected orientation into a preform of a selectedgeometry. Typically, two or more layers of fibers are layered onto asupport and are then needled together simultaneously or in a series ofneedling steps. This process interconnects the horizontal fibers with athird direction (also called the z-direction). The fibers extending intothe third direction are also called z-fibers. This needling process mayinvolve driving a multitude of barbed needles into the fibrous layers todisplace a portion of the horizontal fibers into the z-direction.

A circular needle loom may be utilized to form a circular preform, forexample, for use in creating carbon brake disks. Various textiletechnologies exist for fabricating a continuous carbon feed form for acircular needle loom, including yarn placement, stitch bonding,pre-needling, and loom weaving with conical take-up rolls. Narrow fabricneedle looms may be utilized to produce a continuous spiral textile tapeto be utilized in a circular needle loom to form a circular preform.These spiral textiles may contain warp fibers which lie along the lengthof the textile, and weft fibers which lie along the width of thetextile.

Significantly, prior art looms and other apparatuses for manufacturingcircular preforms suffer from inefficiencies in the manufacturingprocess. For example, a brush bed plate for a circular needle loom maybe utilized to prepare a net shape brake preform. A rotary brush bedplate may be utilized to meet the transport and needling specificationsof a thicker fibrous structure like a brake disk preform. However,maintenance and cleaning of the brush bed plate, and removal of thefinished preform from the bed plate create extra steps in the needlingprocess. These extra steps, among other reasons, substantially add tothe time required to manufacture the preform, resulting in reducedefficiency, lower output and increased cost. Such brush bed plates aretherefore generally not suitable for high production rates, and it isdesirable to develop a system and method for increasing the efficiencyof the manufacturing process to result in higher production rates andreduced costs

Furthermore the brush bed plate does not always provide sufficientanchorage of the bottom layers, resulting in some cases of preformtransport interruption during fabrication. The characteristics of thebrush may change over time, thus resulting in higher maintenance andpossibly in higher part to part characteristic variations than a smoothbed plate.

Additionally, existing systems and methods for manufacturing circularpreforms may produce preforms that have undesirable properties. Forexample, a soft brush bed plate is compliant, and this compliancy mayresult in preforms with lower than desirable fiber volume. The lowerthan desirable fiber volume may result in a preform that is of lowerquality.

Another reason for the deficiencies in the prior art with respect toquality of the preforms and the manufacturing efficiency is due to thecomplexities involved in working with a spiral textile. For example, thecurvature of the spiral textile may require circuitous routes from atextile reel or feed system to the circular needle loom. Additionally,the texture and structure of the textile makes it difficult to depositlayers of the spiral textile on the circular needle loom. Furthermore,existing layering and needling processes make it difficult to remove theneedled preform from the needle loom.

Significantly, prior art mechanisms and methods for transporting aspiral textile from a loom (where the textile is woven) to a circularneedle loom require much more space in order to deliver the spiraltextile in a complex path to the circular needle loom. This complex pathis utilized in order to maintain the weave and overall shape of a spiraltextile from the time it leaves the fabric needle loom to the time it isdeposited in the circular needle loom. For example, the spiral textilemay by layered horizontally on a spool as illustrated in FIG. 1, suchthat it is removed from the spool and oriented to be disposedhorizontally on a circular needle loom. As can be appreciated, such aconfiguration requires that the textile tape change directions from thespool to the circular needle loom, resulting in a circuitous path fromthe spool to the loom.

It is thus desirable to develop a system and method for preparing netshape preforms from a continuous textile spiral feed that are not onlysuitable for high production rates with a high degree of repeatability,but that are also capable of producing preforms of a higher quality, forexample, with a higher fiber volume. It is also desirable to developsystems and methods that utilize various mechanisms in conjunction withpositional structure and/or to create positional structure of the spiraltextile to facilitate layering and needling the spiral textile in anefficient manner to produce high quality needled preforms. Furthermore,it is desirable to create needled preforms in a manner that facilitatessimplified removal of the preform from the needle loom. Moreover, it isdesirable to develop a circular needle loom that reduces waste generatedduring the process of creating the brake disks.

Additionally, it is desirable to develop a mechanism for moreconveniently transporting the spiral textile tape. It is furtherdesirable to reduce the amount of space required to transport the spiraltextile. Moreover, it is desirable to transport the spiral textile tapewhile reducing distortions in the weave of the spiral textile that aregenerated in existing spiral textile transport mechanisms

SUMMARY OF THE INVENTION

In order to address the deficiencies outlined above, various embodimentsof a circular needle loom comprise a stationary bed plate for receivinga spiral textile. Engagement members may be disposed next to thestationary bed plate, such that they interface with a positionalstructure of the spiral textile that is used to rotate the spiraltextile around the stationary bed plate. A conical roller deploys thespiral textile on the stationary bed plate. The circular needle loom mayfurther comprise a needling zone to needle the spiral textile to createa needled preform. In accordance with an embodiment, the engagementmembers rotate the spiral textile around the stationary bed plate untila predetermined number of layers are deposited on the stationary bedplate. Utilizing a stationary bed plate facilitates creating a needledpreform with a higher fiber volume than those preforms created by priorart systems and methods.

The positional structure, according to various embodiments, may includea sacrificial structure comprising one or both of a sacrificial edge anda fiber loop. Further, the engagement members of the loom comprisespikes that engage the positional structure and rotate the spiraltextile on the stationary bed plate in a manner resulting in increasedmanufacturing efficiency of a needled preform.

In an embodiment, the circular needle loom further comprises an insidesupport disposed about an inside portion of the stationary bed plate,and/or an outside support disposed about an outside portion of thestationary bed plate. The engagement members are positioned next to atleast one of the inside support and the outside support. The engagementmembers may further comprise clamps to secure the spiral textile to atleast one of the inside support and the outside support, and at leastone of the inside support and the outside support rotate with respect tothe stationary bed plate to facilitate rotating the spiral textilearound the stationary bed plate. In an embodiment, the circular needleloom further comprises spikes located by at least one of the insidesupport and the outside support, and the spikes penetrate the positionalstructure to secure the spiral textile with the clamps to facilitaterotating the spiral textile around the stationary bed plate.

According to various embodiments, the engagement members comprise wheelswith spikes that engage the positional structure to rotate the spiraltextile around the stationary bed plate. The stationary bed platecomprises circumferential spike grooves into which the spikes on thewheels pass as the wheels rotate.

A method for needling a spiral textile to create a needled preform witha higher quality and in a more efficient manner comprises receiving thespiral textile on a bed plate of a circular needle loom and engaging apositional structure of the spiral textile. The spiral textile is thenrotated around the circular needle loom until a predetermined number oflayers of the spiral textile have been deposited on the bed plate. Thespiral textile is then needled by the needle loom to create the needledpreform.

In accordance with various embodiments, a spiral textile comprises aninside diameter and an outside diameter. A weft tow extends from theinside diameter to the outside diameter, and a positional structure islocated next to and/or is attached to the weft tow. The positionalstructure may also be proximate to the inside diameter and/or theoutside diameter of the textile. Further, the positional structurefacilitates positioning the spiral textile in a desired manner withrespect to a circular needle loom in order to create a needled preform.Such positional structure overcomes deficiencies with prior art spiraltextiles, for example, because the positional structure enablesproduction of needled preforms with higher fiber volume.

In various embodiments, the positional structure is a sacrificialstructure comprising loops, ridges and/or sacrificial edges. Thepositional structure may be formed from synthetic, natural, carbonand/or other materials. In an embodiment, the sacrificial structureextends from about 0.15 inches to about 1.0 inch from the insidediameter and/or the outside diameter, and the sacrificial structure maybe burned off and/or otherwise removed from the spiral textile and/orthe needled preform. Further, in an embodiment, the sacrificialstructure may extend about 3/16 of an inch from the inside diameterand/or outside diameter.

According to an embodiment, the positional structure is a fiber loop. Aloop weft tow in the spiral textile extends from the outside diameter tothe inside diameter of the textile, and the fiber loop is connected tothe loop weft tow. The fiber loop and the loop weft tow may comprisecarbon fibers, natural fibers, and/or synthetic fibers. In variousembodiments, the fiber loop is created during weaving of the spiraltextile in a narrow fabric needle loom. However, in an embodiment, thefiber loop is attached to the loop weft tow by stitching and/or thermalbonding after weaving the spiral textile in the narrow fabric needleloom.

The positional structure, according to various embodiments, interfaceswith an engagement mechanism on the circular needle loom. The engagementmechanism may include a wheel, a clamp, a spike and/or other engagementmechanism. The positional structure in conjunction with the engagementmechanism facilitates layering and needling the spiral textile in anefficient manner to produce high quality needled preforms. Furthermore,the positional structure facilitates simplified removal of the preformfrom the needle loom.

In accordance with an embodiment, a circular needled preform comprises aplurality of layers of a spiral textile needled together by a circularneedle loom. A weft tow with a first end and a second end is located inthe spiral textile. A positional structure interfaces with the first endof the weft tow and/or the second end of the weft tow. The positionalstructure also interfaces with an engagement mechanism of the circularneedle loom in order to deposit the plurality of layers of the textileand facilitate needling the textile to create the needled preform.During and/or after the needling process, the positional structure maybe removed from the spiral textile.

In various embodiments, methods for creating a circular needled preformfrom a spiral textile comprise weaving a weft tow from an insidediameter to an outside diameter of the spiral textile into a pluralityof warp tows, with the plurality of warp tows being spaced between theinside diameter and the outside diameter. Sacrificial fibers areattached to the weft tow and/or the plurality of warp tows, with thesacrificial fibers being located next to the inside diameter and/or theoutside diameter of the textile. An engagement mechanism on a circularneedle loom engages the sacrificial fibers to facilitate moving thespiral textile on the circular needle loom. The spiral textile is movedon the circular needle loom until a predetermined number of layers ofthe spiral textile are deployed on the loom. In an embodiment, thesacrificial fibers are removed from the spiral textile to create thecircular needled preform.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood with reference to thefollowing drawing figures and description. Non-limiting andnon-exhaustive descriptions are described with reference to thefollowing drawing figures. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingprinciples. In the figures, like referenced numerals may refer to likeparts throughout the different figures unless otherwise specified.Further, because the disclosed fibers, tows and yarns (and theirorientations) in practice are very small and closely packed, the figuresherein may show exaggerated fiber width and spacing in order to moreclearly illustrate the fiber orientations.

FIG. 1 illustrates a prior art textile spool;

FIG. 2 illustrates a spiral textile with a sacrificial edge according toan embodiment;

FIG. 3 illustrates a portion of a spiral textile with sacrificial fibersaccording to an embodiment;

FIG. 4 illustrates a spiral textile with fiber loops according to anembodiment;

FIG. 5A illustrates a top view of a needle loom according to anembodiment;

FIG. 5B illustrates a sectional side view of a needle loom outerrotating ring with pins and clamps according to an embodiment;

FIG. 6A illustrates a top view of a needle loom with a stationary bedplate according to an embodiment;

FIG. 6B illustrates a sectional side view of a needle loom with astationary bed plate and with wheels according to an embodiment;

FIG. 7A illustrates a partial side sectional view of a needle loom withlayers of a textile according to an embodiment;

FIG. 7B illustrates a partial top view of a needle loom with a supportguide according to an embodiment;

FIG. 8A illustrates a top view of a needle loom with a rotational bedplate according to an embodiment;

FIG. 8B illustrates a sectional side view of a needle loom with arotational bed plate according to an embodiment;

FIG. 9A illustrates a top view of a needle loom with a rotational bedplate and with wheels according to an embodiment;

FIG. 9B illustrates a sectional side view of a needle loom with arotational bed plate and with wheels according to an embodiment;

FIG. 9C illustrates a sectional side view of a needle loom with arotational bed plate according to an embodiment;

FIG. 10A illustrates a sectional side view of a needle loom with astationary bed plate according to an embodiment;

FIG. 10B illustrates a top view of a needle loom with a stationary bedplate according to an embodiment;

FIG. 11 illustrates a top view of a circular needle loom with spikes onrotational support elements according to an embodiment;

FIG. 12 illustrates a sectional side view of a circular needle loom witha wheel according to an embodiment;

FIG. 13 illustrates a sectional side view of an outer rotating supportof a circular needle loom with movable fingers to engage a textile inpins according to an embodiment;

FIG. 14A illustrates a perspective view of a textile reel according toan embodiment;

FIG. 14B illustrates a side view of a textile reel with a tapered barrelaccording to an embodiment;

FIG. 14C illustrates a sectional side view of a textile reel with aspiral textile wound around a barrel of the textile reel;

FIG. 15 illustrates a perspective view of a textile reel with a woundspiral textile according to an embodiment;

FIG. 16 illustrates a perspective view of textile reel with a woundspiral textile positioned proximate a circular needle loom according toan embodiment;

FIG. 17 illustrates a side view of a textile reel with articulatedelements hinged to a hub according to an embodiment;

FIG. 18A illustrates a perspective view of a textile reel witharticulated elements hinged to a first hub and disposed in radialelements of a second hub according to an embodiment; and

FIG. 18B illustrates a sectional view of an articulated element nestingat a second hub of the textile reel according to an embodiment.

DETAILED DESCRIPTION

The detailed description of various embodiments herein makes referenceto the accompanying drawing figures, which show various embodiments andimplementations thereof by way of illustration and its best mode, andnot of limitation. While these embodiments are described in sufficientdetail to enable those skilled in the art to practice the embodiments,it should be understood that other embodiments may be realized and thatlogical, electrical, and mechanical changes may be made withoutdeparting from the spirit and scope of the invention. Furthermore, anyreference to singular includes plural embodiments, and any reference tomore than one component or step may include a singular embodiment orstep.

Also, any reference to attached, fixed, connected or the like mayinclude permanent, removable, temporary, partial, full and/or any otherpossible attachment option. Additionally, any reference to withoutcontact (or similar phrases) may also include reduced contact or minimalcontact. Finally, though the various embodiments discussed herein may becarried out in the context of an aircraft, it should be understood thatsystems and methods disclosed herein may be incorporated into anythingneeding a brake or having a wheel, or into any vehicle such as, forexample, an aircraft, a train, a bus, an automobile and the like.

As used herein, the singular forms “a,” “an,” and “the” include pluralreferents unless the context clearly dictates otherwise. As used herein,the terms “for example,” “for instance,” “such as,” or “including” aremeant to introduce examples that further clarify more general subjectmatter. Unless otherwise specified, these examples are embodiments ofthe present disclosure, and are not meant to be limiting in any fashion.

As noted above, existing methods and systems for manufacturing circularpreforms suffer from inefficiencies in the manufacturing process andreduced quality in the finished preforms. In order to address thesedeficiencies, and in accordance with various embodiments, circularneedle looms may be utilized to receive spiral textiles such as thosedisclosed in U.S. Ser. No. ______ entitled, “SPIRAL TEXTILE AND SYSTEMFOR WEAVING THE SAME” (filed on ______). The circular needle loomreceives layers of the spiral textile and needle the layers of thespiral textile to form a net shape preform, such as a net shape brakepreform. For example, spiral textiles may be formed using a narrowfabric needle loom, as also disclosed in U.S. Ser. No. ______. Thispatent application and its disclosure is incorporated herein byreference in its entirety.

According to various embodiments, stationary and/or movable bed platesin a circular needle-punching loom (referred to herein as a “circularneedle loom”) may be utilized to produce net shape preforms, such as netshape carbon preforms for brakes. Such circular needle looms may beadvantageously utilized to form a near net shape needle preform withminimum waste. Stationary bed plates may be smooth bed plates, such thatthe spiral textile rotates over, and with respect to, the stationary bedplate to facilitate layering and/or needling the textile. Movable bedplates may be rotatable bed plates that comprise a surface whichgenerates friction between the bed plate and the spiral textile suchthat the bed plates move and/or entrain the spiral textile to facilitatelayering and/or needling the textile. The circular needle loom comprisesa needling zone, and the spiral textile is entrained through theneedling zone to facilitate creating the preform.

Further, in order to address difficulties that existing systems have inworking with spiral textiles, and in accordance with variousembodiments, mechanisms may be utilized to secure the spiral textile ona movable bed plate and/or to cause the spiral textile to move over,about, across and/or around a stationary bed plate to facilitateneedling the textile. For example, in an embodiment, an engagementmechanism may interface with structure at the outside diameter (“OD”)and/or inside diameter (“ID”) of the textile tape to cause the spiraltextile to move with the movable bed plate. Further, in an embodiment,an engagement mechanism may interface with structure at the OD and/or IDof the textile tape to cause the spiral textile to move over, about,across and/or around a stationary bed plate. Structures for securingand/or moving the textile may be referred to collectively herein aspositional structures and/or textile positional structures.

In accordance with various embodiments, and with reference to FIG. 2,positional structure 27 at the outside and/or inside diameters oftextile tape 10 may be included during and/or after weaving of thespiral textile, for example, by a narrow fabric needle loom. The spiraltextile includes warp 20 and weft 30 fibers. As used herein, the terms“tow” and “cable” include a strand of substantially continuousfilaments. As used herein, the term “yarn” includes a strand ofsubstantially continuous fibers or staple fibers or blends of these;thus the term “yarn” encompasses tow and cable. “Warp” fibers includefibers that lie in the “warp” direction in the textile—i.e., along thelength of the textile. “Weft” fibers include fibers that lie in the“weft” direction in the textile—i.e., across the width of the textile.Warp fibers 20 may be described as being spaced apart with respect tothe weft direction (i.e., spaced apart between the OD and ID of thetextile). Similarly, the weft fibers 30 may be described as being spacedapart with respect to the warp direction.

The spiral textile tape 10 may include weft fibers 30 of varying lengthsto facilitate obtaining a substantially homogeneous fiber volume and/ordensity, and/or to generate a tailorable fiber density that increasestowards the OD of the textile. Positional structure 27 at the OD and IDof the spiral textile may include loops, ridges, sacrificial edges, andthe like, as discussed further below. Where positional structures 27(such as loops, ridges, edges, and the like) are removed aftercompletion of the preform, they may be referred to as sacrificialstructures and/or edges. Any structure that may facilitate moving and/orsecuring the textile is contemplated within the scope of the presentdisclosure. It should be understood that in various embodiments, thepositional structure may only be located at the ID or OD of the textile,or at both the ID and the OD. Such positional structure, as discussedfurther below, facilitates moving and positioning spiral textile 10 inan efficient manner in order to overcome certain deficiencies in theprior art.

In an embodiment, and with continued reference to FIG. 2, a spiraltextile tape 10 includes warp fibers 20 running in the direction oftextile tape 10, and weft fibers 30 across the width of textile tape 10.Some weft fibers 30 may extend substantially across the width of textiletape 10, and some weft fibers 30 may extend from the OD to a pointbetween the OD and the ID of textile tape 10.

In various embodiments, with reference to FIGS. 2 and 3, textile tape 10further includes sacrificial fibers 25 co-woven with warp fibers 20 nearthe OD and ID of textile tape 10. For example, in a carbon textile, warpfibers 20 may comprise carbon fibers, and sacrificial fibers 25 maycomprise synthetic fibers. Sacrificial fibers 25 may be utilized to forma sacrificial edge 27 that is utilized to secure and/or rotate textiletape 10 with respect to the circular loom bed plate, as discussedfurther below. Synthetic sacrificial fibers 25, according to variousembodiments, may burn off during heating of the carbon preform, therebyreducing the cost of the carbon preform with respect to utilizing carbonfibers as the sacrificial fibers. In an embodiment, the excess materialused for transporting the fabric and the preform may be cut followingcompletion of the preform, as discussed below. It should be understoodthat carbon, polymers or any other suitable material may be utilized assacrificial fibers 25 without departing from the scope of the presentdisclosure. In various embodiments, sacrificial edge 27 extends fromabout 0.15 inches to about 1.0 inch from the OD and/or ID of textiletape 10. Further, in an embodiment, the sacrificial edge 27 may extendabout 3/16 of an inch from the OD and/or ID of textile tape 10.

In accordance with various embodiments, a narrow fabric needle loom maybe utilized to weave the sacrificial fibers in the spiral textile inorder to address certain deficiencies with the prior art. During theloom set up, sacrificial fibers 25 are added in the warp direction alongboth sides of the carbon warp fibers 20. During weaving, the carbon weftfibers 30 are interlaced with the synthetic warp fibers 25 to providestrong sacrificial edges 27 to the carbon textile 10.

With reference to FIG. 4, an embodiment of spiral textile tape 10comprises fiber loops 29 proximate the OD and/or ID of spiral textiletape 10. Fiber loops 29 may be an extension of weft fibers 30 and maycomprise the same or different material as weft fibers 30. For example,where weft fibers 30 comprise carbon weft fibers, fiber loops 29 maycomprise an extension of the carbon weft fibers. Where fiber loops 29comprise polymeric fiber loops 29, the polymeric fiber loops may not bepart of the finished preform. For example, polymeric and/or syntheticfiber loops may be burned off or otherwise removed during heating of thecarbon preform. In various embodiments, fiber loops 29 protrude fromabout 0.15 inches to about 1.0 inches from the OD and ID of textile tape10. Fiber loops 29 may be utilized to secure and/or move textile 10 withrespect to the circular needle loom bed plate to overcome deficienciesin the prior art, as discussed further below.

In various embodiments, fiber loops 29 may be created during and/orafter the manufacturing of textile tape 10 on a narrow fabric needleloom. For example, a weft insertion needle in the needle loom mayproduce carbon fiber loops 29 at either end of a carbon weft fiber 30insertion. In an embodiment, a loop weft tow such as polymeric weft tow32 may be inserted with the weft insertion needle, and the needle loommay create loops 29 at either end of polymeric weft tow 32. According toan embodiment, fiber loops 29 may be formed through a separate processthan during the weaving process. After the weaving process, fiber loops29 may be attached to the spiral tape 10 through, for example, stitchingand/or thermal bonding. It should be understood that any mechanism forcreating fiber loops 29 out of any material are contemplated within thescope of the present disclosure.

Various embodiments include mechanisms and/or apparatuses that utilizepositional structure such as sacrificial edge 27 and/or fiber loops 29to secure and/or move textile 10 with respect to a bed plate of acircular needle loom, in order to increase the efficiency ofmanufacturing a needled preform. For example, with reference to FIGS.5A-5B, a stationary bed plate such as smooth circular bed plate 40 isdisposed between rotational outside support element 42 and rotationalinside support element 43. Textile 10 is disposed on stationary bedplate 40, and sacrificial edges 27 are proximate support elements 42,43. Support elements 42, 43 may include pins and/or spikes 41 thatprotrude through sacrificial edge 27, and/or may include retractableclamps 44 to facilitate rotating textile 10 with rotating supportelements 42, 43. Such a configuration facilitates rotating textile tape10 around stationary bed plate 40 with rotating support elements 42, 43.In an embodiment, support elements 42, 43 may comprise a plurality ofindividual support elements disposed around the OD and ID circumferencesof textile tape 10. Rails, chains, belts and other transport/entrainmentmechanisms may be utilized to rotate support elements 42, 43 and/orother types of engagement members disclosed herein.

Rotating support elements 42, 43 continue to rotate with respect tostationary bed plate 40 until a desired number of layers of textile 10are needled with needling boards 12. To accommodate increased thicknessof textile 10 as the number of layers increases, the top surface ofsupports 42, 43 may be recessed. Further, top and/or oblique surfaces ofsupports 42, 43 may be tapered to exert lateral tension on textile 10 tofacilitate making the tape flat under the circumferential forces appliedto textile 10 during transport under needle boards 12.

In various embodiments, retractable clamps 44 have two degrees ofmovement: a vertical motion to pinch and release textile 10, and arotational motion to clear the path for removal of the preform followingcompletion of the needling operation with the desired number of textilelayers. In various embodiments, retractable clamps 44 may be activatedusing pneumatic, hydraulic or electrical systems. Further, in anembodiment, retractable clamps 44 may utilize a swivel motion toretract, such that retractable clamps 44 may have a c-shaped geometryand may be articulated around a horizontal axis. The c-shaped clamps 44swivel toward and away from the textile around that axis to facilitateclamping and releasing the textile.

In an embodiment, clamps 44 and/or spikes 41 are utilized to secure thefirst few bottom layers of the preform. Further, clamps 44 and/or spikes41 may be utilized to secure one or more layers, wherein the number oflayers is determined to facilitate stability of the preform being built,for example, by facilitating moving the preform around the bed plate.Two or more sets of clamps may be controlled in pairs (e.g., one pairconstitutes one inner and one outer clamp) and/or at different times toprovide clamping along the edges of textile 10. For example, a firstpair of clamps may be utilized to secure the first layer of textile 10to supports 42, 43 as the first layer is disposed on the bed plate.Other sets are subsequently activated as the tape moves over the bedplate. For example, certain clamps 44 may be utilized to secure otherareas of the first layer, and certain clamps 44 may be utilized tosecure the second, third, etc. layers.

In various embodiments, it may not be necessary to clamp and/or pinhigher numbers of layers. For example, where the first, second, andthird layers are clamped, it may not be necessary to clamp additionallayers, because clamping the first three layers may be sufficient tofacilitate moving textile 10 with respect to bed plate 40. However, itshould be understood that any number of layers may be clamped and/orpinned, such that the number is sufficient to facilitate moving textile10 with respect to bed plate 40.

According to an embodiment, and with reference to FIGS. 6A-6B, elements42, 43 may be stationary, and motorized wheels 46 with spikes 47 mayrotate textile 10 with respect to stationary bed plate 40 and stationarysupport elements 42, 43. Spikes 47 may penetrate positional structure 27to facilitate moving textile 10, and spikes 47 may be dimensioned topenetrate a desired number of layers of textile 10. Wheels 46 may bespring-loaded and/or adjustable to allow the wheels to move upward asadditional layers of textile 10 are deposited on bed plate 40. Accordingto various embodiments, and with reference to FIGS. 7A-7B, wheels 46 andspikes 47 may penetrate the first one through four layers of textile 10.In embodiment, spikes 47 penetrate a sufficient number of layers toprovide stability to the preform and/or to facilitate rotating textile10 about stationary bed plate 40. Retractable support guides 48 may beutilized to prevent subsequent layers from being penetrated by spikes47, because the subsequent layers rest on support guides 48. Forexample, support guides 48 may be inserted after a predetermined numberof layers of spiral textile 10 have been needled. In an embodiment,support guides 48 are inserted starting with the support guide upstreamof the first pair of wheels 46 where the spiral tape enters the needleloom.

In order to overcome certain inefficiencies in the prior art discussedabove, and in accordance with various embodiments, positional structuresuch as sacrificial edge 27 and/or fiber loops 29 may be utilized tosecure textile 10 to a rotational bed plate or to rotate textile 10 overa stationary bed plate. For example, with reference to FIGS. 9A-9B,rotational bed plate 50 may be utilized to create layers of textile 10to facilitate needling textile 10 into a circular preform. Rotationalbed plate 50 may comprise a honeycomb or circumferential groovestructure to facilitate rotating textile 10 with bed plate 50. Such bedplates may not exhibit the same compliancy as brush bed plates of theprior art, and therefore facilitate manufacturing preforms with higherfiber volume.

In various embodiments, circular needle loom 7 includes rotatable clamps54 that are movable with rotational bed plate 50, and that furtherfacilitate rotating textile 10 with bed plate 50. For example, clamps 54may clamp a sacrificial edge and/or fiber loops 29 to secure textile 10to bed plate 50. Clamps 54 may be located at the OD and ID of textile 10and/or bed plate 50.

Clamps 54 may be movable in a rotational direction and in a verticaldirection. For example, clamps 54 may rotate into place when fiber loops29 are in the proper location, and the clamps may then move verticallytowards bed plate 50 to contact fiber loops 29 and secure textile 10 tobed plate 50. Then, when sufficient layers have been deposited, clamps54 may move vertically away from bed plate 50 and then rotate away fromfiber loops 29 to facilitate removal of the preform. In an embodiment,after rotating away from fiber loops 26, clamps 54 may move verticallydownward so as to be below the surface of bed plate 50. In thisposition, the preform created by layers of textile 10 may beautomatically pushed away from bed plate 50, for example, with the useof a dedicated arm or other mechanism to remove the preform. Suchremoval, for example, increases the efficiency in the manufacturingprocess of the preform and thereby reduces costs associated withexisting systems.

In various embodiments, different sets of clamps 54 may be utilized tosecure textile 10 to bed plate 50. For example, as the first layer oftextile 10 is deposited, a first set of clamps 54 near a feeding zone 53for textile 10 (i.e., where textile 10 is fed onto bed plate 50), may beengaged with fiber loops 29. Further sets of clamps 54 may be activatedas additional layers of textile 10 are deposited.

According to various embodiments, mechanisms may be utilized to secure aspiral textile to a rotational bed plate to facilitate needling layersof the textile into a preform. For example, with reference to FIGS.9A-9C, wheels 56 may be utilized to secure textile 10 to rotational bedplate 50. Wheels 56 may be spring loaded and biased towards bed plate50. As bed plate 50 rotates, wheels 56 roll over fiber loops 29, therebysecuring textile 10 to rotational bed plate 50. As additional layers oftextile 10 are deposited, wheels 56 move vertically to accommodate theadditional layers of fiber loops 29, but still maintain pressure onfiber loops 29 due to the spring biasing the wheels towards bed plate50. When a desired number of layers of textile 10 have been deposited,wheels 56 may be rotated away from fiber loops 29 to facilitate removingthe preform from bed plate 50.

In various embodiments where textile 10 may be moved across a stationarybed plate 40, for example, with reference to FIGS. 10A-10B, clampsand/or motorized wheels 56 with spikes 51 may drive textile 10 aroundstationary bed plate 40. Wheels 56 may be located at the OD and/or ID oftextile 10. The axis of rotation of wheels 56 is parallel to stationarybed plate 40, such that wheels 56 roll across the surface of bed plate40. Bed plate 40 includes circumferential spike grooves 52 that aredimensioned to allow spikes 51 to pass below the surface of bed plate 40when wheels 56 rotate. Such a configuration allows spikes 51 to passthrough fiber loops 29 of textile 10 and thereby drive textile 10 aroundbed plate 40 with the rotation of wheels 56. Wheels 56 may be biasedwith a spring towards bed plate 40, such that wheels 56 move verticallyto accommodate a desired number of layers of textile 10 as the preformis created. In an embodiment, a support guide similar to support guide48 (see FIGS. 7A-7B) may be utilized to limit the engagement of wheels56 and spikes 51 to the first few layers of the spiral textile.

In an embodiment, clamps are used in connection with rotational supportelements at the OD and/or ID of the stationary bed plate to create aneedled preform. For example, where a spiral textile comprises loops fora positional structure, clamps may be utilized to clamp the loops to therotational support elements to facilitate rotating the spiral textilearound the stationary bed plate. In an embodiment, spikes may or may notbe used in connection with the loops, clamps and/or rotational supportelements. For example, spikes may be advantageously used to position theinitial spiral textile layers.

In various embodiments, and with reference to FIGS. 11-13, a stationarybed plate 40 with outside support element 42 and inside support element43 may facilitate layering and needling a spiral textile in needlingzone 12. Spikes 74 placed along outside support element 42 and/or insidesupport element 43 interface with various positional structuresdisclosed herein, which are associated with the spiral textile.

A conical reel 110 may contain the fabric supply for the circular needleloom 10.

The conical reel 110 may be placed substantially vertically abovestationary bed plate 40 in a section located upstream of needling zone12. In various embodiments, the spiral textile is unwound and placed onbed plate 40 and/or on previously needled layers of the textile. Once apredetermined length of the edges of the spiral textile is pinned tospikes 74, the rotational movement of outside support element 42 andinside support element 43 facilitate driving the textile around bedplate 40 and through needling zone 12. In an embodiment, the drivingmechanism to unwind the fabric from reel 110 may be supplemented by anactive conical roller 114 placed between reel 110 and needling zone 112,as illustrated in FIG. 11.

In various embodiments, and depending on the amount of textile stored onreel 110, the unwinding of the textile may be facilitated by a motorizedshaft driving reel 110. The speed of the shaft may be coordinated withthe speed of outside support element 42, inside support element 43,and/or any other mechanisms supporting the unwinding and transport ofthe spiral textile. Furthermore the conical roller may advantageouslyfacilitate the initial positioning of the fabric, for example, byproperly orienting the fabric and exerting a downward force on thefabric.

In various embodiments, mechanisms may be utilized to press the spiraltextile over spikes 74 and/or to otherwise secure the spiral textile torotational outside support element 42 and rotational inside supportelement 43. For example, and with reference to FIG. 13, engagementmechanisms such as pressing bars, fingers, and/or combs 94 may bepositioned along sections of the inside and/or outside support elementsto push the sacrificial edges of the spiral textile onto spikes 74. Inan embodiment, and with reference to FIG. 12, rotating wheels 56equipped with brushes and/or fingers 83 may be used to push thesacrificial edges into spikes 74. Further, in an embodiment, the shaftof the conical roller drives the conical roller and two additionalwheels with bristles and/or fingers to apply pressure on the innerand/or outer edges of the textile.

It should be understood that, although fiber loops 29 and sacrificialedge 27 have been disclosed to facilitate securing a spiral textile to abed plate or rotating the spiral textile over the bed plate, anystructure may be utilized to secure or rotate the textile withoutdeparting from the scope of the present disclosure. For example, anypositional structure that may be utilized to increase the efficiency andreduce the cost of manufacturing a needled preform is contemplatedwithin the scope of the disclosure. Further, in various embodiments, onetype of structure may be utilized on the OD of the textile, and the sameor different structure may be utilized on the ID of the textile.Additionally, wheels, clamps, and/or combinations of the same may beutilized to facilitate securing and/or rotating the textile.

Further, it should be understood that any of the various mechanisms formoving the textile about the circular needle loom may be used inconnection with a rotational and/or stationary bed plate. For example, atextile with loops 29 may be moved about a stationary bed plate by beingclamped onto support elements located at the ID and/or OD of the bedplate. As the support elements rotate, the textile moves around the bedplate until a sufficient number of layers are created and needled. Anysecuring and/or entrainment mechanism disclosed herein may be used incombination with stationary bed plates, rotational bed plates,stationary support elements and/or rotational support elements tofacilitate needling the spiral textile into a circular preform.

In connection with the systems and methods discussed above, a spiraltextile may be needled into a needled preform in a more efficient mannerthat currently available in the prior art. For example, in accordancewith various embodiments, a method for creating a circular preform froma spiral textile comprises weaving a weft tow from an inside diameter toan outside diameter of the spiral textile into a plurality of warp towsspaced between the inside diameter and the outside diameter. Sacrificialfibers are then co-woven or attached to the weft tow and/or and theplurality of warp tows, such that the sacrificial fibers are next to theinside diameter and/or the outside diameter of the spiral textile.

After the sacrificial fibers are incorporated into the spiral textile,the spiral textile is transported to a bed plate of a circular needleloom. The bed plate may be either stationary or movable as discussedabove. The loom may engage a positional structure of the spiral textile,for example, by engaging a sacrificial structure such as a loop or asacrificial edge with a wheel, clamp, spike, and the like. The loom thenrotates the spiral textile around the circular needle loom until apredetermined number of layers of the spiral textile have been depositedon the bed plate. In a needling zone, the first two layers, and anysubsequent layers, of the spiral textile are then needled to create theneedled preform. In an embodiment, once a sufficient number of layershave been needled, the needled substructure becomes the securing andtransport structure for the subsequent needled layers, and theengagement members may no longer be necessary. In various embodiments,the engagement mechanisms may be removed from the positional structuresuch that the needled preform may be efficiently removed from the loom.Further, in various embodiments, the sacrificial structure may beremoved, for example, by burning (e.g., during a furnace process usedfor preparing the carbon brake disk) or cutting, in order to finalizethe needled preform.

As noted above, existing reels, spools and other mechanisms for storingand deploying spiral textiles, for example, reels such as thoseillustrated by prior art FIG. 1, require substantial space and complexrouting schemes to deploy the spiral textile on a circular needle loomin order to create a needled preform. Further, prior art mechanismsrequire substantial care in order to maintain the weave of the spiraltextile. In order to address these and other deficiencies, and inaccordance with various embodiments, a storage device such as a spool,reel and the like may be utilized to advantageously receive a spiraltextile tape from a loom in a manner that more easily and efficientlymaintains the shape and weave of the spiral textile tape with lessdistortion than prior art mechanisms. The tape may be prepared with arelatively loose weave such that various embodiments substantiallyminimize any distortion of the tape that would shift the fibers in thetape around.

In accordance with various embodiments, a spiral textile tape istransported from the loom where the spiral textile tape is created toanother location. For example, a conical take off system may comprise aspool 110 that facilitates taking the spiral textile off of a narrowfabric needle loom after weaving the textile. The spiral textile tapemay then be transported, for example, on spool 110, to a circular needleloom where the spiral textile tape is removed from spool 110, and thenlayered and needled into a preform of a selected geometry as discussedabove.

According to an embodiment, and with reference to FIGS. 14A-14C, a spool110 facilitates substantially maintaining the shape and weave of aspiral textile tape 150 both when the textile 150 is wound around abarrel 140 of spool 110 as it is received from the first loom and as thetextile tape is unwound from the spool 110 and layered in the secondloom to create a circular preform.

For a textile having a straight shape—i.e., the textile lies in astraight line—a standard spool may be used to receive the textile fromthe first loom. For example, a standard spool may comprise a cylinderthat receives the straight textile. However, a spiral textile tapeaccording to various embodiments has a helical shape—i.e., when a spiraltape is flat, it falls in a circle and not a straight line. Therefore, acylinder may not sufficiently receive a spiral textile tape withoutdistorting the weave and/or shape of the spiral textile tape.

Thus, according to various embodiments, and with reference to FIG. 14C,a spool 110 that receives a spiral textile tape 150 comprises asubstantially conical section 140. For example, a frustum of a cone maybe disposed between two hubs 120, 130, and the frustum of a cone mayreceive the spiral textile 150. The frustum may have differentcharacteristics depending on the curvature, inside diameter, outsidediameter, weave or other structure or characteristic of the spiraltextile. The spool 110 with the cone section 140 may maintain theoverall geometry of the spiral tape 150 as well as the fiber orientationfollowing weaving of the tape in the first loom. For example, the conesection 140 may be tapered such that the textile tape 150 may be woundaround cone section 140 in a manner that orients a face 155 of textile150 such that textile face 55 is substantially parallel to cone section140.

According to an embodiment, each reel holds sufficient textile tape forat least a single preform. In this manner, less space is required tomaintain the spiral textile tape near the circular needle loom, becausethe reel is sized appropriately for the preform that is being created.Also, limiting the storage to a single preform reduces distortion in thefabric that may occur when too many layers are wound on the reel.Further, segmenting the textile tape into individually-sized reelsfacilitates automation of the preform manufacturing process. Forexample, multiple reels may be loaded automatically or manually into afeed device proximate the circular needle room, and one reel may beloaded for each preform needling process. Additionally, in variousembodiments, each reel may hold sufficient tape for a plurality ofpreforms, or multiple reels may be utilized for a single preform.

In accordance with an embodiment, substantially vertical reels 110 maybe utilized to wind the spiral tape 150 from a narrow fabric needleloom. As the weaving process is progressing, the spiral tape 150 iswound from the narrow fabric needle loom onto conical barrel 140 of reel110. Reel 110 may then be transported to a substantially verticalposition above a circular bed plate of a needle punch loom and/or acircular needle loom. Such a method facilitates collecting, moving, andstoring a woven spiral tape substantially without distortion and feedingthe fabric in a more simplified path from the reel to the circular bedplate. Furthermore, with reference to FIG. 16, reel 110 may be locatedcloser to circular needle loom 160 than prior art spiral textile storagemechanisms. For example, textile tape 150 is advantageously oriented onreel 110 so that it may be deployed and/or directly layered on circularneedle loom 160 without reorienting textile tape 150. This configurationovercomes difficulties associated with prior art reels where the tapeexits a reel and is then fed through a complex path to reorient thetextile tape with respect to a circular needle loom.

In accordance with various embodiments, the textile tape may be routedfrom one reel to another, either manually or automatically (e.g., usinga robot) during which process the tape may be cut, such as by“kiss-cutting,” to facilitate cutting short fibers at the surface oftape to enable transfer of the short fibers in the z direction withrespect to the tape. Such a cutting process is described in more detailin U.S. patent application Ser. No. 12/536,649 entitled, “Method AndSystem For Enabling Z Fiber Transfer In Needled Preform” (filed on Aug.6, 2009), the entirety of which is incorporated herein by reference. Forexample, a first reel may be located proximate a narrow fabric needleloom, and the textile may be wound around the first reel as the weavingprocess is progressing. Then the textile may be unwound from the firstreel and wound around a second reel proximate the circular needle loom.The cutting may occur between the first reel and the second reel.

According to an embodiment, and with reference to FIGS. 14A-14C and 15,a reel 110 for a spiral textile 150 comprises opposing hubs 120 and 130and a barrel 140 disposed between the hubs. Barrel 140 may be in theshape of a frustum of a cone. For example, the end of barrel 140 that isproximate hub 120 may comprise one diameter, and the end of barrel 140that is proximate hub 130 may comprise a larger or smaller diameter. Invarious embodiments, barrel 140 may have any geometry thatadvantageously facilitates winding a spiral textile tape 150 aboutbarrel 140 in a manner that maintains a weave and shape of the textiletape 50.

In an embodiment, and with reference also to FIG. 16, reel 110 mayfurther facilitate unwinding textile 150 from barrel 140 onto a circularneedle punch loom bed plate 160. Textile 150 includes a face 155 that isdisposed in a substantially parallel manner to barrel 140. Bed plate 160also receives face 155 of textile tape 150 in a substantially parallelfashion such that textile tape 150 lies substantially flat on bed plate160. Because face 155 of textile tape 150 is substantially parallel tobarrel 140 of reel 110 and to bed plate 160 of a circular needle punchloom, reel 110 may be disposed close to bed plate 160 and substantiallyvertically with respect to bed plate 160. This configuration facilitatesreducing space required for routing textile tape 150 to bed plate 160.Further, such configurations overcome difficulties associated with priorart reels because reel 110 facilitates orienting textile tape 150 closeto a circular needle loom because it is not necessary to reorient thetextile tape prior to layering it on the circular needle loom.

In various embodiments, reel 110 advantageously winds and dispensesspiral textile tapes having different dimensions, such as ODs and IDs,different weaving patterns, and various other different characteristics.For example, with respect to FIGS. 17 and 18A-18B, reel 110 may beadvantageously adaptable to different types of spiral tapes as discussedbelow.

According to an embodiment, reel 110 comprises a first hub 120, whichincludes a plurality of articulated elements 145 that are rotatablyattached to and/or associated with first hub 120. Second hub 130includes a plurality of radial elements 143 that extend from the centerof second hub 130 to the outside of second hub 130. Radial elements 143contain slots 147 that receive articulated elements 145. Radial elements143 each include a plurality of slots 147 to advantageously provide anumber of positions wherein articulated elements 145 may be located.Articulated elements 145 may be moved from one slot 147 to another slot147 on radial element 143 in order to increase or decrease the angle ofarticulated element 147 with respect to first hub 120 and second hub130.

Collectively, articulated elements 145 may function as barrel 140(discussed above) about which a textile tape may be wound, stored, andthen unwound. As such, articulated elements 145 may be referred to asbarrel elements to describe the functionality of elements 145. Dependingon the geometry, weave, composition and/or other characteristics of thespiral textile, barrel elements 145 may be moved from one slot 147 toanother slot 147 to facilitate receiving the textile tape.

In accordance with various embodiments, any number of articulatedelements 145, radial elements 143, and slots 147 may be utilized toaccommodate a variety of textile types, shapes, geometries and the like.Collectively, articulated elements 145 may provide a surface upon whicha spiral textile tape may be wound. For example, collectively,articulated elements 145 may form a substantially frusto-conical surfacethat receives the spiral textile tape. In an embodiment, articulatedelements may form a triangle, square, pentagonal, octagonal and the likestructures to receive the spiral textile in an orientation thatfacilitates directly deploying the spiral textile on a circular needleloom, without a need for reorienting the textile tape with respect tothe circular needle loom.

Although this disclosure illustrates and describes various embodiments,equivalents and modifications will occur to others who are skilled inthe art upon reading and understanding of the disclosure. Variousembodiments include all such equivalents and modifications, and islimited only by the scope of the following claims.

Additionally, benefits, other advantages, and solutions to problems havebeen described herein with regard to various embodiments. However, thebenefits, advantages, solutions to problems, and any elements that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as critical, required, or essentialfeatures or elements of the invention. The scope of the invention isaccordingly to be limited by nothing other than the appended claims, inwhich reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” Moreover, where a phrase similar to “at least one of A, B, and C”or “at least one of A, B, or C” is used in the claims or specification,it is intended that the phrase be interpreted to mean that A alone maybe present in an embodiment, B alone may be present in an embodiment, Calone may be present in an embodiment, or that any combination of theelements A, B and C may be present in a single embodiment; for example,A and B, A and C, B and C, or A and B and C. Furthermore, no element,component, or method step in the present disclosure is intended to bededicated to the public regardless of whether the element, component, ormethod step is explicitly recited in the claims. No claim element hereinis to be construed under the provisions of 35 U.S.C. 112, sixthparagraph, unless the element is expressly recited using the phrase“means for.” As used herein, the terms “comprises”, “comprising”, or anyother variation thereof, are intended to cover a non-exclusiveinclusion, such that a process, method, article, or apparatus thatcomprises a list of elements does not include only those elements butmay include other elements not expressly listed or inherent to suchprocess, method, article, or apparatus.

1. A circular needle loom, comprising a stationary bed plate forreceiving a spiral textile; engagement members disposed proximate thestationary bed plate, wherein the engagement members interface with atleast one of the spiral textile and a positional structure of the spiraltextile to facilitate rotating the spiral textile around the stationarybed plate; and a conical roller for deploying the spiral textile on thestationary bed plate.
 2. The circular needle loom of claim 1, furthercomprising a needling zone proximate the stationary bed plate to needlethe spiral textile.
 3. The circular needle loom of claim 1, wherein theengagement members rotate the spiral textile around the stationary bedplate until a predetermined number of layers are deposited on thestationary bed plate.
 4. The circular needle loom of claim 1, whereinthe positional structure includes a sacrificial structure comprising atleast one of a sacrificial edge and a fiber loop.
 5. The circular needleloom of claim 1, wherein the engagement members comprise spikes thatengage the positional structure and rotate the spiral textile on thestationary bed plate.
 6. The circular needle loom of claim 1, furthercomprising at least one of: an inside support disposed about an insideof the stationary bed plate; and an outside support disposed about anoutside of the stationary bed plate, wherein the engagement members aredisposed proximate at least one of the inside support and the outsidesupport.
 7. The circular needle loom of claim 6, wherein the engagementmembers comprise clamps to secure the spiral textile to at least one ofthe inside support and the outside support.
 8. The circular needle loomof claim 7, wherein at least one of the inside support and the outsidesupport rotate with respect to the stationary bed plate to facilitaterotating the spiral textile around the stationary bed plate.
 9. Thecircular needle loom of claim 8, further comprising spikes disposed onat least one of the inside support and the outside support, wherein thespikes penetrate the positional structure to secure the spiral textilewith the clamps and rotate the spiral textile around the stationary bedplate.
 10. The circular needle loom of claim 1, wherein the engagementmembers comprise wheels with spikes that engage the positional structureto rotate the spiral textile around the stationary bed plate.
 11. Thecircular needle loom of claim 10, wherein the stationary bed platecomprises circumferential spike grooves into which the spikes on thewheels pass as the wheels rotate.
 12. The circular needle loom of claim6, wherein the inside support and the outside support are stationarywith respect to the stationary bed plate.
 13. The circular needle loomof claim 12, wherein the engagement members comprise wheels with spikesthat pass into circumferential spike grooves in the inside support andoutside support to facilitate rotating the spiral textile around thestationary bed plate.
 14. The circular needle loom of claim 13, furthercomprising a support guide to limit a predetermined number of layers ofthe spiral textile that are engaged by the spikes.
 15. The circularneedle loom of claim 1, wherein the engagement members are retractableto facilitate removing a needled preform from the circular needle loom.16. A system for positioning a spiral textile on a circular needle loom,comprising: a rotational bed plate that receives a spiral textile;engagement members disposed proximate the rotational bed plate, whereinthe engagement members interface with a positional structure of thespiral textile to secure the spiral textile to the rotational bed plate;and a conical roller for deploying the spiral textile on the rotationalbed plate.
 17. The system of claim 16, wherein the positional structurecomprises at least one of a sacrificial edge and a fiber loop.
 18. Thesystem of claim 16, wherein the engagement members comprise retractableclamps that secure the positional structure to the rotatable bed plate,wherein the retractable clamps rotate with the rotational bed plate andthe spiral textile.
 19. The system of claim 16, wherein the engagementmembers comprise wheels that roll with respect to the rotational bedplate, wherein the positional structure passes under the wheels as thespiral textile rotates with the rotational bed plate.
 20. A method forneedling a spiral textile to create a needled preform, the methodcomprising: receiving the spiral textile on a bed plate of a circularneedle loom; engaging a positional structure of the spiral textile;rotating the spiral textile around the circular needle loom; depositinga predetermined number of layers of the spiral textile on the bed plate;and needling the spiral textile to create the needled preform.
 21. Aspiral textile, comprising: an inside diameter and an outside diameter;a weft tow extending from the inside diameter to the outside diameterand a positional structure proximate the weft tow and proximate at leastone of the inside diameter and the outside diameter, wherein thepositional structure facilitates positioning and transporting layers ofthe spiral textile with respect to a circular needle loom to create aneedled preform.
 22. The spiral textile of claim 21, further comprisinga warp tow, wherein the positional structure is proximate the warp tow.23. The spiral textile of claim 21, wherein the positional structureincludes a sacrificial structure comprising at least one of loops,ridges, and sacrificial edges.
 24. The spiral textile of claim 22,further comprising sacrificial warp fibers proximate the outsidediameter and the inside diameter.
 25. The spiral textile of claim 24,wherein the sacrificial warp fibers comprise synthetic fibers, andwherein the warp tow comprises carbon fibers.
 26. The spiral textile ofclaim 24, wherein the sacrificial warp fibers and the warp tow comprisecarbon fibers.
 27. The spiral textile of claim 25, wherein the weft towcomprises carbon fibers, and wherein the sacrificial warp fibers and theweft tow form a sacrificial structure.
 28. The spiral textile of claim27, wherein the sacrificial structure extends from about 0.15 inches toabout 1.0 inch from at least one of the inside diameter and the outsidediameter.
 29. The spiral textile of claim 27, wherein the sacrificialstructure is at least one of burned off and removed after the spiraltextile is formed into the needled preform.
 30. The spiral textile ofclaim 21, wherein the positional structure comprises a fiber loop. 31.The spiral textile of claim 30, further comprising a loop weft towextending from the outside diameter to the inside diameter, and whereinthe fiber loop is connected to the loop weft tow.
 32. The spiral textileof claim 31, wherein the fiber loop comprises carbon fibers, and whereinthe loop weft tow comprises carbon fibers.
 33. The spiral textile ofclaim 31, wherein the fiber loop comprises synthetic fibers, and whereinthe loop weft tow comprises synthetic fibers, wherein the fiber loop iscreated during weaving of the spiral textile in a narrow fabric needleloom.
 34. The spiral textile of claim 31, wherein the fiber loopcomprises synthetic fibers, wherein the loop weft tow comprises carbonfibers, and wherein the fiber loop is attached to the loop weft towafter weaving of the spiral textile in a narrow fabric needle loom. 35.The spiral textile of claim 34, wherein the fiber loop is attached tothe loop weft tow by at least one of stitching and thermal bonding. 36.The spiral textile of claim 21, wherein the positional structureinterfaces with an engagement mechanism on the circular needle loom. 37.The spiral textile of claim 36, wherein the engagement mechanismcomprises at least one of a wheel, a clamp, and a spike.
 38. A circularneedled preform, comprising: a plurality of layers of a spiral textileneedled together by a circular needle loom; a weft tow disposed in thespiral textile, wherein the weft tow has a first end and a second end;and a positional structure interfacing with at least one of the firstend of the weft tow and the second end of the weft tow, wherein thepositional structure interfaces with an engagement mechanism of thecircular needle loom to facilitate depositing the plurality of layers,and wherein the positional structure is removable from the spiraltextile.
 39. The circular needled preform of claim 38, wherein thepositional structure comprises at least one of a fiber loop and asacrificial edge.
 40. A method for creating a circular needled preformfrom a spiral textile, comprising: weaving a weft tow from an insidediameter to an outside diameter of the spiral textile into a pluralityof warp tows spaced between the inside diameter and the outsidediameter; attaching sacrificial fibers to at least one of the weft towand the plurality of warp tows proximate at least one of the insidediameter and the outside diameter; engaging the sacrificial fibers withan engagement mechanism on a circular needle loom; moving the spiraltextile on the circular needle loom to deploy a predetermined number oflayers of the spiral textile on the circular needle loom; and removingat least a portion of the sacrificial fibers after needling the spiraltextile.